T67 2 Intarder EST48 81995985322 ENG

Electrical System
Intarder EST 48
2002 | 1 | 2 3 4 | 5 | 6 | 7 | 8 | 9 | 10 | 11 | 12
Publication no.: System Description

81.99598-5322 2nd edition T 67
MAN Nutzfahrzeuge Aktiengesellschaft Elektrische Anlage

Dachauer Str. 667 oder Postfach 50 06 20 Systembeschreibung T 67 (2. Ausgabe)
80995 MÜNCHEN 80976 MÜNCHEN - englisch -
Printed in Germany
Electrical System
Intarder EST 48
System Description T 67 (2nd edition)
81.99598-5322
ELECTRICAL SYSTEM
We reserve the right to make modifications in the course of further development
 2002 MAN Nutzfahrzeuge Aktiengesellschaft
Reprinting, copying or translation is not allowed without written permission from MAN
All rights under the copyright law are strictly reserved by MAN
VSWY / WT 03.2002 Übersetzung + Satz: emes GmbH

Friedrichshafen
0.01 - 2 T 67
ELECTRICAL SYSTEM
Table of contents
Electrical system........................................................................................................................... 0
Table of contents.......................................................................................................................... 0.11 - 1
Abbreviations................................................................................................................................ 0.13 - 1
General information...................................................................................................................... 1
Notes on safety ............................................................................................................................ 1.20 - 1
System description....................................................................................................................... 2
Intarder EST 48 design ................................................................................................................ 2.01 - 1
CAN messages and CAN diagnosis............................................................................................. 2.01 - 3
Function split ................................................................................................................................ 2.01 - 3
Components ................................................................................................................................. 2.01 - 4
Display.......................................................................................................................................... 2.01 - 7
Interfaces to other systems .......................................................................................................... 2.01 - 8
Functional description ................................................................................................................. 3

Electronic control unit ................................................................................................................... 3.01 - 1
Coolant temperature sensor......................................................................................................... 3.01 - 2
Proportional valve......................................................................................................................... 3.01 - 3
Accumulator solenoid valve (2/3-way valve) ................................................................................ 3.01 - 4
Steering column stalk ................................................................................................................... 3.01 - 4
Sustained-action brake switch...................................................................................................... 3.01 - 7
Bremsomat (braking control) mode .............................................................................................. 3.01 - 8
Pulse generator KITAS 2170........................................................................................................ 3.01 - 9
ABS control .................................................................................................................................. 3.01 - 10
Intarder check lamp...................................................................................................................... 3.01 - 10
Component description................................................................................................................ 4
Electronic control unit ................................................................................................................... 4.01 - 1
Coolant temperature sensor......................................................................................................... 4.02 - 1
Proportional valve......................................................................................................................... 4.03 - 1
Accumulator solenoid valve (2/3-way valve) ................................................................................ 4.04 - 1
Steering column stalk ................................................................................................................... 4.05 - 1
Sustained-action brake switch...................................................................................................... 4.06 - 1
Pulse generator KITAS 2170........................................................................................................ 4.07 - 1
Wiring diagrams............................................................................................................................ 6
Table of contents.......................................................................................................................... 6.00 - 1
Guide to using the wiring diagrams .............................................................................................. 6.01 - 1
Overview, Intarder EST 48 (TG-A) ............................................................................................... 6.05 - 2
Overview, Intarder EST 48 (R02/R03).......................................................................................... 6.06 - 2
Wiring diagram, Intarder EST 48 (TG-A)...................................................................................... 6.20 - 2
Wiring diagram, drive module, Intarder EST 48 (R02/R03).......................................................... 6.21 - 2
Wiring diagram, Intarder EST 48 (R02/R03) ................................................................................ 6.22 - 2
Diagnosis....................................................................................................................................... 8
Diagnosis socket .......................................................................................................................... 8.03 - 1
Fault code..................................................................................................................................... 8.10 - 1
On-board diagnosis ...................................................................................................................... 8.10 - 5
SPN - fault code list ...................................................................................................................... 8.10 - 7
SPN - fault code description ......................................................................................................... 8.11 - 1
System structure, K-lines ............................................................................................................. 8.15 - 1
T 67 0.11 - 1
ELECTRICAL SYSTEM
Abbreviations As of: 04.02
a Acceleration
ABE General operating permit
ABS Anti-lock brake system
ABV Anti-skid system
AC Air conditioning
ACC Adaptive cruise control
ACK Autocheck
ADC Analog-digital converter
ADR International agreement for the transport of dangerous goods
AGB Automatic road speed limiter
AGND Analog ground
AGR Exhaust gas recirculation (EGR)
AHK Trailer coupling
AHV Trailer brake valve
ALB Automatic load-dependent brake
AMA Antenna mast system
ANH Trailer/semitrailer
AS Automated gearbox
ASD Trailer socket
ASM Trailer control module
ASR Anti-spin regulator
ASV Trailer control valve
ATC Automatic temperature control
ATF Automatic transmission fluid
AU Emission test
AV Exhaust valve
AVS Automatic gear preselection
BA Operator’s manual
BBA Service brake system
BBV Service brake valve
BKR Brake power regulator
BUGH Front heater
BV Back-up valve
BVA Brake wear indicator
BVS Brake wear sensor
BVV Brake wear sensor supply
BW German Army
BWG Brake value sensor
BZ Brake cylinder
CAN Controller area network

CAN-H CAN-high data line
CAN-L CAN-low data line
CATS Computer-assisted testing and diagnostic system
CCVS Cruise control vehicle speed
CKD Completely knocked down
CNG Compressed natural gas
CPU Central processing unit
CRT Continuously regenerating trap
CS Comfort shift
DAHL Roof ventilator

DBR Auxiliary brake relay
DECKE Cover (for doors)
DF Speed sensor
DFÜ Data transmission
DIA Diagnosis and information display
T 67 0.13 - 1
ELECTRICAL SYSTEM
Abbreviations
DIAK Diagnosis, K-line (data line)

DIAL Diagnosis, L-line (interrogation line)
DIAR Diagnosis, further interrogation
DIN German industrial standard
DKE Throttle valve increase (ASR control)
DKH Roof duct heating
DKL Roof flaps
DKR Throttle valve reduction (reduction request from ASR to EDC/EMS)
DKV Throttle valve specification (load sensor signal from EDC/EMS pedal value sensor)
DLB Compressed air brake system
DM Diagnostic message
DNR Drive - Neutral - Reverse (selector switch for automatic gearbox)
DPF Diesel particulate filter
DRM Pressure control module
DS Pressure sensor
DSV Pressure control valve
DV Throttle valve
DWA Anti-theft protection system
DZG Rpm sensor
DZM Rev counter
EBS Electronic brake system

ECAM Electronically controlled air management
ECAS Electronically controlled air suspension
ECE Emergency shut-off to ECE 36
ECU Electronic control unit
EDC Electronic diesel control
EDM Electronic diesel consumption meter
EDR Maximum speed governor
EEC Electronic engine controller
EEPROM Electrically erasable and programmable read-only memory
EFR Electronic shock absorber control (ESAC)
EFS Electrical driver’s seat
EHAB Electro-hydraulic shut-off device
ELAB Electrical shut-off device
ELF Electronic air suspension
EMS Electronic throttle control (ETC)
EMV Electromagnetic compatibility (EMC)
EOL End-of-line (programming)
EP Injection pump
ER Engine retarder (engine brake)
ESAC Electronic shock absorber control
ESP Electronic stability program
ESR Electric sun-blind
EST Electronic control unit
EV Intake valve
EVB Exhaust valve brake
FAP Driver’s area

FAQ Frequently asked questions
FBA Parking brake system
FDR Dynamic handling control
FFR Vehicle management computer (VMC)
FGB Road speed limiter (RSL)
FGR Road speed governor (RSG)
FHS Cab
FIN Vehicle identification number (VIN)
FM Vehicle management
FMI Failure mode identification
0.13 - 2 T 67
ELECTRICAL SYSTEM
Abbreviations
FMR Vehicle/engine management

FOC Front omnibus chassis (bus/coach chassis with front-mounted engine)
FSCH Windscreen heater
FSG Ground reinforcement system
FSH Window/mirror heating
FTW Driver’s partition
FUNK Radio communication unit
FZA Destination system
GDK Controlled diesel catalytic converter

GEN Alternator
GET Gearbox
GGVS Regulations for the transport of hazardous goods
GND Ground
GP Gearbox planetary gear group (range-change box)
GS Gearbox control
GV Gearbox splitter gear group (splitter box)
HA Rear axle
HBA Auxiliary brake system
HGB Maximum road speed limiter
HGS Hydraulic gearshift
HLUE Hydrostatic fan
HOC Rear omnibus chassis (bus/coach chassis with rear-mounted engine)
HSS Highside switch
HST Main control panel
HU Main inspection
Hz Hertz (number of cycles per second)
HZA Bus stop indicator system
HZG Auxiliary rpm sensor
IBEL Interior lighting

IBIS Integrated on-board information system
IC Integrated circuit
ID Identification
IMR Integrated mechanical relay (starter control)
INA Information indicator (e.g. check lamp)
IR Individual control (ABS)
IRM Modified individual control (ABS)
ISO International Standards Organisation
IWZ Incremental angle/time measuring system
KBZ Combination brake cylinder

KFH Fuel filter heater
KITAS Kienzle intelligent tachograph sensor
KLI Air-conditioning system
KNEEL Kneeling
KSM Customer-specified control module
KSW Customer’s special request
KWP Key word protocol (protocol for MAN-cats diagnosis)
LBH Air reservoir

LCD Liquid crystal display
LDA Manifold-pressure compensator (boost control)
LDF Boost pressure sensor
LDS Air spring/damper system
LED Light emitting diode
LF Air suspension
LGS Lane guard system
T 67 0.13 - 3
ELECTRICAL SYSTEM
Abbreviations
LL Idling speed
LLA Idling speed increase
LLR Idling speed control
LNA Steering trailing axle
LNG Liquefied natural gas
LOE Steering oil monitor
LPG Liquified petroleum gas
LWR Headlight beam regulator
M-TCO Modular EU tachograph

MAB Solenoid valve shut-off (engine shut-off by means of high-pressure solenoid valve in injection
pump)
MAN-cats MAN computer assisted testing and diagnostic system)
MAR Solenoid valve shut-off relay (redundant engine shut-off relay)
MDB Engine speed range
MES Fuel metering control
ML Midline
MMI Man-machine interface
MOTB Engine brake
MP Engine power box (cable duct on engine block)
MR Engine governor - ASR
MSG Engine control unit (EDC)
MV Solenoid valve
MZ Diaphragm cylinder
n rpm
NA Power take-off (PTO)
NBF Needle movement sensor
NES New electronic structure
NFZ Commercial vehicle
NLA Trailing axle
NSL Rear fog lamp
NSW Front fog lamp
OBDU On-board diagnostic unit

OC Occurrence count (errors/faults)
OEAB Oil separator
OENF Oil top-up
p Pressure
PBM Pulse breadth modulation (à also see PWM)
PLM Programmable logic module
PSG Pump control unit (EDC)
PTO Power take-off
PWM Pulse width modulation (à also see PBM)
RA Repair manual
RAH Interior heating
RAM Random access memory
RAS Rear axle steering
RAS-EC Rear axle steering with electronic control
RDRA Tyre pressure control system
RDS Radio data system
RET Retarder
RKL Priority vehicle light
RLV Relay valve
RME Rape seed oil methyl ester (biodiesel)
ROM Read only memory
0.13 - 4 T 67
ELECTRICAL SYSTEM
Abbreviations
SA Special equipment
SAE Society of Automotive Engineers
SAMT Semi-automatic mechanical transmission
SB Service outlet
sec Second
SER Series (production)
SG Control unit
SH Select-high control (ABS)
SKD Semi-knocked down
SL Select-low control (ABS)
SML Side marker light
SPN Suspect parameter number
STA Engine start/stop
SWR Headlight cleaning system
t Time
TC Traction control
TCM Trailer control module
TCO Tachograph
TKU Technical customer document
TMC Traffic message channel
TRS Technical road transport directives
TSC Torque speed control (braking torque)
TUER Door control
UBat Battery voltage

UDS Crash recorder
v Velocity/vehicle speed
VA Front axle
VG Transfer case
VLA Leading axle
WA Maintenance manual
WAB Water separator
WaPu Water pump - Intarder
WLE Swap-body unit
WR Warning relay
WS Position sensor
WSK Torque converter and clutch unit
z Braking rate/deceleration
ZBR Central on-board computer
ZBRO Central on-board bus computer
ZDR Intermediate speed governor (ISG)
ZE Central electrical system (CES)
ZR Central computer
ZS Central lubrication
ZUSH Auxiliary heater
ZWS Time-based maintenance system
λ Slip
µ Coefficient of friction
µC Microcontroller (microprocessor)
T 67 0.13 - 5
GENERAL INFORMATION
Notes on safety
The following sections include summaries of important regulations listed according to major topics. The
intention is to provide the knowledge needed to avoid accidents which could lead to injury, damage and
environmental pollution.
Additional instructions are included in the Operator’s Manual that is provided with the vehicle.
Important:
Accidents may happen in spite of all precautionary measures having been taken. In such an eventuality,
obtain immediate medical assistance from a doctor. This is particularly important if the accident
involves skin contact with corrosive acid, fuel penetration under the skin, scalding by hot oil, antifreeze
spraying into eyes etc.
Regulations for preventing accidents leading to injury to personnel.
Only authorised technical personnel are allowed to perform inspection, adjustment and repair work.
• Secure the vehicle to prevent it from rolling away.

• Support the frame when working on the pneumatic or spring suspension
system.
• Secure units during their removal.
• Only authorised personnel are allowed to start and operate the engine.
Do not approach moving parts of a running engine too closely. Do not wear
baggy clothing.
• Do not touch the engine with your bare hands when it is at operating
temperature: Risk of burns!
• Keep the area around the engine, ladders and steps free from oil and grease.
Accidents caused by slipping can have serious consequences.
• Only use tools that are in perfect condition. Damaged or widened spanners can
slip: Risk of injury!
• No-one is allowed to stand under an engine suspended from a crane hook.
- Keep all lifting tackle in good condition -.
• Collect any brake fluid that emerges. Treat brake fluid as hazardous waste!
Comply with the safety regulations for preventing environmental pollution.
• Brake fluid is toxic! Do not allow it to come into contact with food or open
wounds.
• Do not open the coolant circuit until the engine has cooled down. If it does need
to be opened whilst the engine is at operating temperature, follow the
instructions in the "Maintenance and care" section in the Operator’s Manual.
• Do not attempt to retighten or open pipe lines and hoses (lubricating oil circuit,
coolant circuit and possible subsequent hydraulic oil circuit) whilst they are
pressurised: Fluid spraying out represents an injury hazard!
• Do not hold your hands under the jet of fuel when checking the injector nozzles.
Do not inhale fuel vapours.
T 67 1.20 - 1
GENERAL INFORMATION
• Always disconnect the batteries before working on the vehicle electrical system.
Important! Oxyhydrogen gas may form in enclosed battery boxes. When the
batteries are disconnected, this gas may be ignited by sparks produced by other
continuously operating consumers, the tachograph etc. that cannot be shut down.
Blow compressed air through the battery box before disconnecting the batteries!
• Only tow-start the vehicle if the batteries are connected (minimum charge 40%)!
Do not use a boost-charger to jump-start the vehicle! Always disconnect the
positive and negative leads before boost-charging batteries!
• Disconnect the batteries and recharge them every 4 weeks if the vehicle is not in
use.
Caution! Battery acid is poisonous and corrosive. Battery gases are explosive.
• Follow the manufacturer’s instructions for handling batteries.
• Measure voltage only using suitable measuring devices!
The input resistance of a measuring device should be at least 10 MΩ.
• The ignition must be switched off before the wiring harness plugs of electronic
control units are disconnected or connected up!
When performing electrical welding work, connect up the "ANTIZAP SERVICE
MONITOR" (MAN item number 80.78010.0001) or the improved SES-1 version
(MAN item number 80.78010.0002) in accordance with the instructions supplied with
the device.
If this device is not available, disconnect the batteries and join the positive cable to
the negative cable in order to make a conductive connection.
Always earth the welding equipment as close as possible to the welding area. Do not
lay the cables to the welding equipment in parallel to electrical cables in the vehicle.
For further accident prevention measures, please refer to the "Leaflets for welders".
The frame is not intended for use as an earth return!
• If attachments are to be retrofitted to the vehicle – e.g. a taillift – additional earth
lines with adequate cross-section must be fitted as well. Otherwise the earth
connection may be created along wire cables, wiring harnesses, gearbox shafts,
gears etc. Severe damage could result.
• If painting work is to be carried out, do not expose the electronic components

to high temperatures (max. 95 °C) for more than brief periods; a time of up to
around 2 hours is permissible at a maximum of 85 °C. Disconnect the batteries.
Plastic tubes (polyamide)

Important! – Risk of damage and fire!
• The warning sign opposite can be found on the co-driver’s door below the door
lock. It warns you against welding or drilling near to plastic tubes.
1.20 - 2 T 67
GENERAL INFORMATION
Limited liability for accessories and parts
In your own interests, you are recommended to use only accessories expressly approved by MAN and
genuine MAN parts for your MAN vehicle. The reliability, safety and suitability of these parts and
accessories have been determined specifically for MAN vehicles. Despite constant market observation, we
cannot judge the aspects of other products, nor can we accept responsibility for them – even if they have
been officially approved by the German TÜV technical inspection authorities or some other official body.
Bodies and special attachments

Comply with the safety instructions and regulations issued by the bodymaker in question if bodies or
special attachments are fitted.
Taking out of operation or putting into storage

The special measures described in MAN Works Standard M 3069 Part 3 apply if buses or trucks are to be
withdrawn from service or stored for a period longer than 3 months.
T 67 1.20 - 3
SYSTEM DESCRIPTION
Intarder EST 48 design
The Intarder is a wear-free hydrodynamic transmission brake and can be used to full effect when the driver
wishes to brake the vehicle either at high road speeds or during long descents.
Using the Intarder helps preserve the service brakes. This means the full power of the service brakes is
available in the event of an emergency.
The driver can change gear at any time whilst the vehicle is being braked by the Intarder.
The Intarder also helps ensure smoother and, therefore, more economical driving.
The Intarder is fitted at the output end of the gearbox.
Its main components are:

− Housing
− Stator
− Rotor
− Valve housing
− Electronic control unit
− Heat exchanger with oil accumulator
The braking effect is achieved by the oil that is in the Intarder. When activated by the vehicle management
computer, the Intarder is filled with the quantity of oil required to achieve the desired braking torque.
Once activated, the Intarder takes approx. 0.75 seconds to reach the desired braking torque. Once
deactivated, the Intarder takes approx. 0.3 seconds to reduce the desired braking torque to zero (e.g. as
with ABS control).
The job of the Intarder pump is to deliver the oil from the gearbox sump to the Intarder circuit via a filter.
When the Intarder is activated, the accumulator solenoid valve is opened and the accumulator volume is
drained into the Intarder chamber. This results in a shortening of the response time.
The proportional valve is activated by the electronic control unit, causing the Intarder to be filled with the
required quantity of oil.
A gear ratio on the gearbox input shaft drives a rotor at high speed. The oil accelerated by the rotor blades
is slowed down by the blades of the stationary turbine wheel (stator) and the braking energy is converted
into heat energy. Here, the oil is diverted, slowed down and returned to the rotor. The slowed down and,
therefore, heated oil brakes the rotor and, therefore, the vehicle.
The braking torque generated is applied to the vehicle drive train via the spur gear stage. The braking
torque is also retained during gearshifts.
The heat is dissipated to the connected oil/water heat exchanger in the cooling circuit. A temperature
sensor measures the coolant temperature and sends this information to the electronic control unit. The
vehicle must be braked using the service brake in the event of Intarder failure or excessive Intarder
temperature.
Advantages of the Intarder:
− Fast response times

− Common oil circuit shared with the gearbox
− Lightweight design
− Low operating temperatures
− "Bremsomat mode" (constant road speed when driving downhill)
− All power take-offs that can be combined with the gearbox can still be fitted
IMPORTANT: The Intarder is not a parking brake!
T 67 2.01 - 1
SYSTEM DESCRIPTION
Design (electrical)
1 Intarder EST 48 (mounted on the gearbox)

2 Electronic control unit (A144)
3 Coolant temperature sensor (B134)
4 Proportional valve (Y133)
5 Accumulator solenoid valve (2/3-way valve) (Y134)
6 Steering column stalk (A437)
7 Sustained-action brake switch (S479)
8 Vehicle management computer (A403)
9 Central on-board computer (A302)
10 Display (on the instrument panel A407)
11 Tachograph MTCO 1324 (recorder A408)
12 Pulse generator KITAS 2170 (B110)
T-CAN Drive train CAN databus

I-CAN Instrumentation CAN databus
2.01 - 2 T 67
SYSTEM DESCRIPTION
CAN messages and CAN diagnosis
The diagnostic capability of the electronic control unit has been changed to CAN diagnosis.
Receive messages
The messages received by the Intarder are primarily torques specified by the vehicle management
computer as well as information messages from other control units which provide vehicle status signals.
Send messages
The send messages primarily contain Intarder status information that is made available to other control
units in the CAN databus.
Request
If requested to do so, the electronic control unit can send the Intarder Mmax curve to the vehicle
management computer so that the latter can calculate the correct desired torques as a function of the
current Intarder speed.
The control unit determines the necessary currents for the proportional valve and the accumulator solenoid
valve based on the required desired torque changes – as well as calculating the actual static and dynamic
Intarder torque – and cyclically returns this information to the CAN databus.
Function split
Scope of Intarder tasks:

− Setting of a requested braking torque
− Power limiting as a function of the coolant temperature
− Power limiting as a function of the road speed
Scope of electronic brake system (EBS) tasks

− Recording the brake pedal travel
− Providing an "ABS active signal"
Scope of the vehicle management computer (FFR) tasks

− Recording the controls
− Requesting a braking torque
− Activating the engine brake
Temperature limiter
The temperature limiter is designed to protect the vehicle cooling system and the Intarder.
If a specified limit temperature is exceeded, the Intarder braking torque is reduced until, when a 2nd limit
temperature is exceeded, only a minimum Intarder torque is modulated.
If the temperature limiter is active and if the constant temperature function is additionally parameterised, the
control unit attempts to slowly re-increase the braking torque according to a defined algorithm until this
temperature limit is reached. If it is exceeded, however, the braking torque must be reduced until, finally, a
constant temperature is set at high braking power. This allows better utilisation of the Intarder's capacity at
high temperatures.
In this case, the control unit only receives and processes one temperature signal from the coolant
temperature sensor in order to protect the Intarder against impermissible temperatures.
T 67 2.01 - 3
SYSTEM DESCRIPTION
Components
Electronic control unit (A144)
The electronic control unit (A144) controls and monitors the Intarder functions.
− Signal from steering column stalk (A437) (braking torque is set)

− Engine speed sensor signal for the Intarder speed (braking power limited to 420 kW)
− Signal from coolant temperature sensor (B134) for the coolant temperature (safety)
− Bremsomat pushbutton signal (Bremsomat activated or deactivated)
− Signal from the EBS/ABS ECU (the Intarder is deactivated when EBS/ABS is active)
Data is transferred to other systems via the "drive train" CAN databus (T-CAN). The control unit is EOL-
programmed (end of line). At the end of the line, the vehicle manufacturer inputs vehicle-specific
parameters alongside the already entered system manufacturer parameters. The entered parameters can
be checked – or changed if necessary – using the MAN-cats diagnostic system.
The Intarder is activated using the steering column stalk (A437). The signal from the steering column stalk
is sent to the vehicle management computer (A403) via the CAN databus (T-CAN).
The vehicle management computer receives the signals of other control units in the form of messages
containing information about the current vehicle status.
The messages received by the electronic control unit (A144) are primarily braking torque specifications.
The control medium for the Intarder is compressed air which is taken from the air tank for the vehicle's
auxiliary consumers.
The braking torque specification is processed in the electronic control unit (A144) using the stored
characteristics and the Intarder is activated.
Coolant temperature sensor (B134)
The temperature sensor sends the coolant temperature to the electronic control unit (A144). If the
temperature is too high, the Intarder is gradually governed back by the electronic control unit.
Proportional valve (Y133)
The Intarder hydraulic unit is activated, the maximum braking power is limited to 420 kW and activated by
the electronic control unit (A144) by means of a pulse width modulation signal. Braking torque control is
implemented via the proportional valve. The braking torque is obtained by setting the steering column stalk.
Accumulator solenoid valve (Y134)
When the Intarder is activated, the accumulator solenoid valve (2/3-way valve) (Y134) opens and the oil in
the Intarder accumulator is drained into the Intarder chamber (faster Intarder response).
Sustained-action brake switch (S479)
The sustained-action brake switch switches the Intarder ECU power supply on or off and links the road
speed governor to the brake and to the Intarder ("intelligent linking").
Switch off: The Intarder can only be operated using the steering column stalk (A437).
Switch on: The Intarder is operated using the steering column stalk (A437). It is also possible to
activate the "Bremsomat" (braking control) function.
2.01 - 4 T 67
SYSTEM DESCRIPTION
Steering column stalk (A437)
The steering column stalk is used to operate the Intarder. There are a total of 6 braking levels. The steering
column stalk movements are recorded by the vehicle management computer (A403). This means that the
electronic control unit (A144) no longer has to be adapted to different controls or sustained-action brake
management concepts.
The Intarder generates a braking torque when requested to do so by the vehicle management computer via
the "drive train" CAN databus (T-CAN).
Intarder operating modes:
− Normal mode:
The driver can obtain a constant braking torque using the steering column stalk. In normal mode, each
braking level on the steering column stalk is assigned a constant braking torque (a constant braking
torque is evenly divided into 6 levels.).
The braking torque evenly increases from level 1 to level 6, the maximum possible value. Braking level
0 means that the Intarder is not active.
− Bremsomat mode:
This mode (also known as braking control mode) allows the vehicle to be kept at a road speed defined
by the driver when driving downhill. The driver can use the button 1 on the end of the steering column
stalk to program in the current road speed whilst driving. The Intarder constantly maintains this road
speed whilst the vehicle is being driven downhill. The road speed limiting is performed by the vehicle
management computer (A403), i.e. the vehicle management computer requests the necessary
sustained-action braking torque from the electronic control unit (A144) via the "drive train" CAN
databus (T-CAN).
The electronic control unit automatically selects the necessary braking level.
Steering column stalk operation
The driver can send three function commands to the vehicle management computer (A403).
Button 1 Vehicles that have no Intarder fitted only have a button which is used
to switch the engine brake on and off.
In vehicles that have an Intarder fitted, this button is pressed to quickly
switch the requested braking torque on or off (depending on the rear axle
load). The rear axle load is communicated to the vehicle management
computer by the EBS electronic control unit.
Move towards + Nudge: Gradual increase in the requested braking torque.

Hold the stalk: Automatic increase in the requested braking torque.
T 67 2.01 - 5
SYSTEM DESCRIPTION
Move towards - Nudge: Gradual decrease in the requested braking torque.

Hold the stalk: Automatic decrease in the requested braking torque.
Note:
If the steering column stalk suffers a defect or interrupt, the maximum braking level that is activated is
the level that matches the number of intact braking level signals.
If there is no braking level 1 signal, the Intarder is deactivated.
Warning and diagnosis light (H145)
The sustained-action brake no longer has a conventional check lamp. Instead, it has a panel of check LEDs
with a display.
Errors detected by the electronic control unit (A144) are communicated to the central on-board computer
(A302) in the form of CAN messages. The central on-board computer activates the check LED (H145) and
the instrument panel display (A407).
When an error is detected, an error number appears on the instrument panel display.
Pulse generator KITAS 2170 (B110)
The pulse generator (B110) and the tachograph (A408) form a tamper-proof unit.
The two components cyclically exchange data.
The pulse generator is mounted on the vehicle gearbox and delivers real-time pulses and coded data for
recording the distance and the road speed.
Brake lamp
The brake lamp is activated by the central on-board computer (A302) based on the information available on
the CAN databus.
ABS mode
Reduction and restoring of the brake torque in the case of ABS is controlled by the vehicle management
computer (A403).
The electronic control unit (A144) does not have to automatically detect ABS mode; it merely has to react
to the specification sent by the vehicle management computer.
2.01 - 6 T 67
SYSTEM DESCRIPTION
Display
The display is integrated in the instrument panel (A407). All information for the driver and workshop is
displayed.
Display segments
Diagnosis
3 2
1 04015-01 = Fault code
2 = Intarder check lamp (H145)
3 = Central warning light (H111)
If the steering column stalk is moved towards + or towards –, "retarder level" 4 and the retarder symbol
with a lower-case number (1-6) 5 appear on the display, the latter on the top right. The number indicates
the current braking level (1-6).
The central on-board computer (A302) receives the corresponding signal from the vehicle management
computer (A403) and forwards it to the instrument panel (A407).
4 5
Retarder level
When the steering column stalk is in position 0, the braking torque is shut off and the display goes out.
T 67 2.01 - 7
SYSTEM DESCRIPTION
Interfaces to other systems
Thanks to its inclusion in the CAN databus, the retarder/Intarder control unit can be networked with
other systems. Data is transferred between the individual systems via the serial "drive train" CAN
databus (T-CAN).
− TG-A
A143 Electronic air suspension/ A403 Vehicle management computer with

electronic shock absorber control terminators, M-CAN and T-CAN
A144 Control, retarder/Intarder A407 Instrumentation
A302 Central computer 2 with terminator, I-CAN A408 Tachograph with terminator, I-CAN
A312 Customer-specified module A409 Electronically controlled air management with
terminator, T-CAN
A330 Gearbox control, Tipmatic AS-Tronic A435 Electronic diesel injection with terminator, M-CAN
A384 Rear axle steering RAS-EC A551 Drive module, oil level sensor
A402 Electronic brake system
I-CAN CAN databus, instrumentation T-CAN CAN databus, drive train

M-CAN CAN databus, engine management
2.01 - 8 T 67
SYSTEM DESCRIPTION
− Buses and coaches R02 and R03 (multiplex)
A408 Tachograph with terminator, I-CAN A144 Control, retarder/Intarder

A435 Electronic diesel injection with A143 Electronic air suspension/
terminator, M-CAN electronic shock absorber control
A403 Vehicle management computer with A330 Gearbox control, Tipmatic AS-Tronic
terminators, M-CAN and T-CAN
A360 Multiplex, central computer A407 Instrumentation
A302 Central computer 2 with terminator, I-CAN A551 Drive module, oil level sensor
A402 Electronic brake system A409 Electronically controlled air management with
terminator, T-CAN
A312 Customer-specified module
Basis-CAN 1 CAN databus, multiplex line 1 I-CAN CAN databus, instrumentation

Basis-CAN 2 CAN databus, multiplex line 2 M-CAN CAN databus, engine management
T-CAN CAN databus, drive train
A411 Multiplex node, front left 1.1 A421 Multiplex node, front right 2.1
A413 Multiplex node, control units 1.3 A422 Multiplex node 2.2
A417 Multiplex node 1.7 A423 Multiplex node, vehicle centre 2.3
A418 Multiplex node, rear right 1.8 A428 Multiplex node, rear left 2.8
R195 Terminator, front, basis CAN 1 R197 Terminator, front, basis CAN 2
R196 Terminator, rear, basis CAN 1 R198 Terminator, rear, basis CAN 2
T 67 2.01 - 9
2.01 - 2 T 67
FUNCTIONAL DESCRIPTION
The voltage supply comes from the central electrical system (A100). The electronic control unit controls
and monitors the Intarder functions.
The control unit processes input signals that it receives via the coolant temperature sensor (B134) and the
"drive train" CAN databus (T-CAN).
The control unit receives braking torque specifications from the steering column stalk (A437). In
"Bremsomat" (braking control) mode, the road speed specified by the driver is maintained when driving
downhill. The control unit automatically engages the braking level (1-6) needed to maintain this road speed.
The signal is sent to the vehicle management computer (A403) where it is converted into a databus format.
From here, the signal is then sent to the central on-board computer (A302) via the CAN databus (T-CAN).
The central on-board computer sends the information to the control unit.
The control unit detects the Intarder output speed via the tachograph, the input speed (engine speed) with
the help of the EDC control unit. The signal for this is sent to the control unit via the CAN databus (T-CAN).
The coolant temperature sensor (B134) sends a coolant temperature signal to the control unit. If the tem-
perature is above a certain level, the control unit gradually reduces the Intarder braking level. In ABS mode,
the vehicle management computer (A403) informs the control unit that the Intarder is not active. In this in-
stance, the control unit does not have to detect this itself. It only has to react to the vehicle management
computer.
If faults occur, the fault codes are sent via the diagnosis K-line to the control unit fault memory where they
are then stored.
The fault codes can be read out using MAN-Cats II.
Connector pin assignment
Connector X1: TG-A R02/R03
Pin Line no. Designation Pin Line no. Designation

1 --- Databus, T-CAN High 1 153 Databus, T-CAN High
2 --- Databus, T-CAN Low 2 154 Databus, T-CAN Low
3-7 --- Not used 3-7 --- Not used
8 43201 K-line, diagnosis 8 16202 Control unit, EBS and
control unit, ECAM
9-18 --- Not used 9-18 --- Not used
T 67 3.01 - 1
Connector X2: TG-A and R02/R03
Pin Line no. Designation

1 43004 F152 Voltage supply, terminal 15
3 31000 Ground
4-6 --- Not used
9 31000 Ground
Connector X3: TG-A and R02/R03

1 --- Not used
2 43104 B134 Temperature sensor, coolant
3 43105 B134 Temperature sensor, coolant
4 --- Not used
5 31105 Y134 2/3-way accumulator solenoid valve
6-9 --- Not used
10 43304 Y133 Proportional valve
11 43305 Y134 2/3-way accumulator solenoid valve
12 43303 Y133 Proportional valve
Connector X4:
Plug housing X4 is not used!
The temperature sensor is installed in the water circuit – return line from Intarder to radiator – and sends
coolant temperature information to the electronic control unit (A144).
The Intarder converts the vehicle's braking energy into heat energy. This causes the oil in the Intarder to
heat up. The heat generated by this process is transferred to the vehicle engine cooling circuit by means of
the connected oil/water heat exchanger.
The temperature is picked up in the Intarder coolant outlet circuit. This allows the electronic control unit
(A144) to control the Intarder.
The maximum coolant temperature is specified in the electronic control unit (A144).
The purpose of the temperature sensor is to detect the temperature of the coolant emerging at the Intarder
heat exchanger outlet. The temperature here must not exceed the maximum of 105 degrees. If the tem-
perature reaches 90 - 100 degrees, the electronic control unit (A144) begins to gradually reduce the In-
tarder braking level (Intarder power reduction).
The following message appears on the display when the Intarder power is reduced (by more than 30%):
"Retarder power adjusted"
3.01 - 2 T 67
Connector pin assignment: TG-A and R02/R03

1 43104 A144 Pin X3/2 - temperature signal, coolant
2 43105 A144 Pin X3/3 - activation B134
Important:
If the temperature sensor fails, the electronic control unit (A144) reduces the braking power to
braking level 2, i.e. to the highest permitted braking level (even if a higher braking level was en-
gaged beforehand).
The Intarder still remains operational even if the braking level is reduced.

The proportional valve activates the Intarder's hydraulic unit. In this instance, the maximum braking power
is limited to 420 kW.
The proportional valve is activated by a pulse width modulation signal sent by the electronic control unit
(A144) and receives a maximum current of 425 mA.
The proportional valve control current is compared with the control pressure during the check.
A change in the control current causes a change in the control pressure.

2 43303 A144 PIN X3/12 - activation, proportional valve
3 43304 A144 PIN X3/10 - activation, proportional valve
T 67 3.01 - 3
Important:
The proportional valve must not be energised with 24 V!
The check must include measurement of the current supplied to the proportional valve from the
electronic control unit (A144) - this current must not exceed 425 mA!
The Intarder is automatically shut off in the event of a proportional valve fault or defect.
Accumulator solenoid valve (2/3-way valve) (Y134)
The 2/3-way accumulator valve is opened when the Intarder is activated. The volume of oil in the oil accu-
mulator is drained into the Intarder chamber. This allows faster Intarder response times.
In the event of a fault or defect, the electronic control unit (A144) shuts off line 43305 for connector X3/PIN 11.
This means that the Intarder always remains operational, although Intarder response times are slower.
The 2/3-way accumulator solenoid valve is energised with 24 V.

1 43305 A144 PIN X3/11 - activation, 2/3-way accumulator
solenoid valve
4 31105 A144 PIN X3/5 - activation, 2/3-way accumulator
solenoid valve (voltage supply, negative)
Important:
In the event of an accumulator solenoid valve fault or defect, the braking power is not reduced, i.e.
the response time is slower after activation.
The voltage supply comes from the central electrical system (A100). The steering column stalk is used to
operate the Intarder. The driver uses the steering column stalk to set a constant braking torque in normal
mode. The steering column stalk can be used to select one of a total of 6 braking levels:
− 1st level: Engine brake

− 2nd level: Engine brake + 20% retarder torque
− 3rd level: Engine brake + 40% retarder torque
− 4th level: Engine brake + 60% retarder torque
3.01 - 4 T 67
The braking torque evenly increases from level 1 to level 6, the maximum possible value. The Intarder is
not active when the steering column stalk is in the "level 0" position.
In "Bremsomat" (braking control) mode, the road speed specified by the driver is maintained when driving
downhill. Once the desired road speed has been reached, the button on the steering column stalk must be
pressed to store this road speed.
The steering column stalk signal is sent to the vehicle management computer (A403) where it is converted
into a databus format.
From here, the signal is then sent to the central on-board computer (A302) via the CAN databus (T-CAN).
The central on-board computer sends the information to the control unit. The control unit (A144) automati-
cally engages the braking level (1-6) needed to maintain this road speed. Signal output is via the CAN
databus (T-CAN).
The driver can activate the "Bremsomat" (braking control) function by moving the steering column stalk to
the "level 0" position. The "Bremsomat" function will not work unless the sustained-action brake switch
(S479) is in the "on" position.
The driver can temporarily deactivate the "Bremsomat" function by moving the steering column stalk to the
"level 6" position (e.g. when higher braking power is briefly required when cornering).
The "Bremsomat" function is reactivated when the driver moves the steering column stalk back to the "level
0" position.
Note:
The Intarder braking power is limited to 420 kW and the Intarder braking force is low at very low road
speeds. The braking power is limited by the reduction of the braking torque as a function of the road speed
(output speed).
Wiring diagram
Voltage
supply (+24 V)
Clock signal
Data signal
Ground
The display (on the instrument panel A407) is activated when the steering column stalk is moved in +
direction or – direction or when the button on the end is pressed. The display indicates the engaged braking
level.
The requested braking torque is switched off when the driver presses the accelerator pedal.
Note:
There is one exception: A warming up function is recognised on the basis of the coolant temperature. It is
possible to actuate the steering column stalk and the accelerator pedal at the same time, provided that the
engine temperature does not exceed 60 degrees.
T 67 3.01 - 5
Connector pin assignment:
TG-A R02/R03

1 31000 Ground 1 31000 Ground
X1642 Earthing point, cab, X618 Distributor, terminal
behind instrument panel board X102, line 31000
2 43553 Clock line 2 43553 Clock line
Vehicle management com- Vehicle management com-
puter (A403 pin X1/6) puter (A403 pin X1/6)
3 --- Not used 3 --- Not used
4 43554 Data line 4 43554 Data line
Vehicle management com- Vehicle management com-
puter (A403 pin X2/10) puter (A403 pin X2/10)
5 --- Not used 5 --- Not used
6 60028 Voltage supply, steering 6 60028 X1693 Crimped connector,
column stalk (F583) line 60028
Technical data:
Operating voltage: 16 - 32 V
Overvoltage: 36 V/1 hour at 40 °C ambient temperature
Test voltage: 27.6 V
Rated voltage: 24 V
Current at 16 V: max. 12 mA (combined with veh. management computer A403)
Current at 32 V: max. 18 mA (combined with veh. management computer A403)
Operating temperature: -40 ....+80 °C
Input: Input resistance: 5 kΩ to 24 V

125 kΩ to ground
Switching points: low < 4 V
high > 10 V
Input capacitance: 1 nF
Output: Maximum input current: 100 mA

Output impedance: 5 kΩ
Output level: low < 0.5 V (100 mA)
high > 5 kΩ at 24 V
Output capacitance: 1 nF
Resistor power: 0.1 W
3.01 - 6 T 67
Sustained-action brake switch (S479)
The voltage supply comes from the central electrical system (A100).
The purpose of the sustained-action brake switch is to switch the voltage supply to the Intarder ECU – and
therefore all the Intarder functions – on or off.
Wiring diagram
Resistor R1 = 2.2 kΩ; resistor R4 = 11 kΩ (location lighting)
TG-A R02/R03

2 60610 FFR pin 1/16 (intelligent 1 31000 Ground
brake function) connected with PIN 7
4 60028 Voltage supply 4 60028 Voltage supply
(terminal 15) (terminal 15)
Fuse F583 Fuse F372
7 31000 Earthing point X1642 5 58000 Fuse F125,
Earthing point, cab, instrument, switch,
behind instrument panel location lighting
8 58000 Location lighting fuse F125 6 60610 FFR pin 1/16
connected with PIN 8
T 67 3.01 - 7
Sustained-action brake switch in "on" position:

When the switch is in this position, the Intarder can be activated when the brake pedal is pressed up to
about a quarter of the way down (brake pedal idle motion, i.e. the service brake is not activated yet). The
Intarder can also be activated using the steering column stalk (A437).
When the brake pedal is used to activate the Intarder, this controls about 0 - 5% of the Intarder power
which, in turn, depends on the load.
The engine brake is also activated, depending on the engine speed.
The braking torque can be increased or reduced using the steering column stalk (A437).
The button on the end of the steering column stalk can be used to switch the Intarder to full power.
Engaged braking levels (1 - 6) can be cancelled either by repressing the button on the end of the steering
column stalk or by pressing the accelerator pedal.
The "Bremsomat" (braking control) function is automatically activated when the cruise control is used, i.e. a
constant road speed can actually be set before driving downhill.
Sustained-action brake switch in "off" position:

The Intarder can only be operated by the steering column stalk (A437).
The engine brake is activated in level 1 and above.
The Intarder can be switched to full power and engaged braking levels can be cancelled just as if the sus-
tained-action brake switch were in the "on" position.
The "Bremsomat" (braking control) function is not available when the switch is in this position.
Bremsomat (braking control) mode
In this mode, the road speed specified by the driver is maintained when driving downhill. The electronic
control unit (A144) selects the necessary braking level.
− The sustained-action brake switch (S479) must be in the "on" position.
− Storing the desired road speed

The driver can store a desired road speed. Press the button on the steering column stalk (A437) as
soon as the desired road speed is indicated on the tachograph. The signal from the steering column
stalk is sent to the vehicle management computer (A403) where it is converted into a databus format.
This information is sent to the central on-board computer (A302) via the CAN databus (T-CAN).
From here, the signal is forwarded to the instrumentation (A407) via the "instrumentation" CAN databus
(I-CAN).
The current road speed is stored by the ECU and the set road speed information is sent to the vehicle
management computer. The data are forwarded from the vehicle management computer to the EDC via
the "engine" CAN databus (M-CAN).
However, this is only the case if there is enough engine power available. In other words, this means that
the Intarder switches itself off automatically if the road speed falls below the stored value. When the
road speed reaches the previously stored value again, the Bremsomat function is reactivated and the
Intarder switches itself back on. A road speed can be stored in any of the braking levels (0 - 6).
The Bremsomat function kicks in at a speed 2 km/h faster than the selected cruise control speed. EOL
(End Of Line) parameterisation makes it possible to define this road speed threshold which remains a
fixed component.
The vehicle management computer takes over system management and, depending on the engine load,
the Intarder braking power is increased.
Another option is to use the brake pedal. If the brake pedal is used to slow the vehicle, the speed of the
vehicle at the time the brake pedal is released is stored (adaptive braking). The road speed remains
stored and is maintained by the Bremsomat as the new road speed, as long as there is enough Intarder
braking torque available. This can be deactivated by pressing the accelerator pedal.
A further option is to fully release the accelerator pedal.

The current road speed is stored. Braking then takes place automatically if the road speed is exceeded
by 2 km/h.
3.01 - 8 T 67
− "Bremsomat" (braking control) function

The braking level selector is in the "level 0" position.
The Bremsomat function only works in level 0. If the stalk is now moved to the "level 0" position, the
Bremsomat function is activated and the Intarder check lamp (H145) starts flashing. The required brak-
ing level is engaged automatically.
The driver can briefly deactivate the Bremsomat function by moving the steering column stalk (A437) to
one of the levels 1 - 6. This may be the case when cornering, for example, if the driver briefly requires
higher braking power.
The Bremsomat function can be cancelled by repressing the button on the end of the steering column
stalk.
The pulse generator and the tachograph form a tamper-proof unit.

The two components cyclically exchange data. The pulse generator is mounted on the vehicle gearbox and
delivers real-time pulses and coded data for recording the distance and the road speed.
Pin Line colour Designation

1 Grey Voltage supply, pulse generator ( UE = 6.5 V)
2 Grey-green Ground U0
3 Grey-brown Real-time signal (rectangular signal)
4 Grey-white Data signal 1/0
Pin 1 and pin 2: The pulse generator is energised.
Pin 3: There is a real-time signal (rectangular signal) that is proportional to the road speed.
This signal is used for recording the distance and the road speed.
Pin 4: There is dialogue between the tachograph and the pulse generator.
When the tachograph requests data, the sensor sends back coded information. The
tachograph checks this information for correctness.
When the vehicle is operational (terminal 15 on), the tachograph sends commands and data to the pulse
generator at regular 10-second intervals.
The pulse generator uses these command codes to compile a coded data record and sends the signals
back to the tachograph.
The tachograph then compares the signals it receives from the pulse generator with its own data record.
A transmission error is recorded if the signals and data do not match.
T 67 3.01 - 9
The real-time signals are checked by the tachograph (programmed number of distance pulses) whilst the
regular data scans are taking place. If the sensor pulses are not correct, a data error is recorded and an er-
ror code is displayed.
The tachograph uses the real-time signal sent by the pulse generator and the programmed number of dis-
tance pulses to generate the "v-pulse" (vehicle speed pulse). It then sends this pulse to the gauge via the
"instrumentation" CAN databus (I-CAN). The gauge interprets the pulse it receives as its sensor signal. The
control unit (A144) detects the Intarder output speed via the tachograph.
ABS control
If the Intarder is deactivated due to ABS being active, there are three different ways to re-activate the In-
tarder:
− If the brake pedal is depressed (sustained-action brake switch S479 in "on" position), the Intarder is
deactivated whilst ABS is active and automatically re-activated afterwards.
− If the steering column stalk (A437) is used (sustained-action brake switch S479 in "off" position), the
Intarder is deactivated whilst ABS is active and can then only be reactivated if braking level 0
was selected previously.
− If the "Bremsomat" function is active and ABS is active, the Intarder is deactivated and automatically
re-activated afterwards.
Intarder check lamp (H145)
A yellow check lamp is used to indicate the Intarder operating status as well as Intarder faults.
As soon as the driver starts the vehicle, the Intarder system automatically checks that the check lamp is
working correctly. If no errors are detected after the check, the check lamp goes out.
When the Intarder is active (sustained-action brake switch S479 in "on" position), the check lamp comes on
when the brake pedal is pressed.
Furthermore, when the Intarder is active (sustained-action brake switch S479 in "off" position), the check
lamp comes on when the steering column stalk (A437) is actuated.
The braking torque is only set, i.e. the check lamp comes on whilst the "Bremsomat" function is activated,
when the vehicle is in motion.
If an Intarder error occurs, this is indicated as an error on the display (on the instrument panel A407) in text
form.
Using the Intarder does not affect the gearbox shift sequence and the Intarder braking power is largely
maintained when the clutch is pressed (to change gear).
Important:
The Intarder should only be used very carefully in poor weather conditions (black ice, wet roads).
The Intarder only acts on the driven axle(s). The vehicle may start to skid. There is a serious risk of
accidents. Make sure the sustained-action brake switch S479 is in the "off" position to prevent in-
advertent or incorrect operation. This is particularly in important in the case of vehicles not
equipped with ABS.
Make sure that the engine speed never falls below 1600 rpm before and during downhill driving.
Otherwise, sufficient cooling of the coolant can not be guaranteed.
If necessary, shift down a gear to increase the engine speed and, therefore, the water pump and fan
power.
3.01 - 10 T 67
COMPONENT DESCRIPTION

A144
Design
The housing contains a printed circuit board with a

multipoint connector. The control unit electronic
system is equipped with integrated circuits, micro-
controllers and other electronic components.
Installation position
TG-A:
The electronic control unit is installed in the centre

console in the lowest slot on the left next to the
central electrical system (remove device cover).
A144
R02/R03:
The electronic control unit is installed on the right in

the area of the rear axle on an equipment board
(auxiliary switchboard), as seen looking towards the
front of the vehicle.
A144
T 67 4.01 - 1
Design
B134
The temperature sensor is a sensor that measures
the temperature of the coolant – return line from
Intarder to radiator.
It has a 2-pole connection is connected to the elec-
tronic control unit which then receives and processes
the signal sent by the temperature sensor.
The coolant temperature sensor is installed in the

water circuit – return line from Intarder to radiator.
B134
T 67 4.02 - 1
Design
Among other things, the proportional valve consists Y133

of a magnetic coil with an internal resistance of
23 - 33Ω.
It has a 2-pole connection and is connected to the
electronic control unit which supplies the proportional
valve with a pulse width modulation signal.
The proportional valve is mounted on the left of the

Intarder.
Y133
T 67 4.03 - 1
Accumulator solenoid valve (2/3-way valve)

(Y134)
Y134
Design
Among other things, the 2/3-way/accumulator sole-

noid valve consists of a magnetic coil with an internal
resistance of 120 - 130Ω.
It has a 2-pole connection and is connected to the
electronic control unit which deactivates the corre-
sponding line in the event of an accumulator sole-
noid valve defect. It is in contact with the Intarder oil
accumulator which is drained into the Intarder cham-
ber as soon as the Intarder is operated, thus opening
the accumulator solenoid valve.
The 2/3-way accumulator solenoid valve is located

on the right of the Intarder.
Y134
T 67 4.04 - 1
Design 1
A437
The steering column stalk consists of a lever and a
button. The button 1 is located on the end of the
steering column stalk. The lever can be used to in-
crease or reduce the braking torque level by level.
The button is used to activate the Intarder at full
power (fast activation or deactivation of the braking
torque). This button enables the driver to program in
the current road speed whilst the vehicle is in motion
("Bremsomat" braking control mode).
It is connected with to sustained-action brake switch
and to the vehicle management computer where the
data from the steering column stalk are recorded.
A437
TG-A:
The steering column stalk is located on the right-

hand side of the vehicle steering column.
R02/R03:
The steering column stalk is located on the right-

hand side of the vehicle steering column.
A437
T 67 4.05 - 1
Sustained-action brake switch (A479)

S479
Design
The sustained-action brake switch is a switch with 8

connections and contains an LED for night-lighting.
It is designed to link the road speed governor with
the brake and the Intarder.
The sustained-action brake switch is electrically con-
nected to the steering column stalk and to the vehi-
cle management computer where the on/off states
are then recorded.
TG-A:
S479
The switch is located on the dashboard on the right
edge of the instrument panel.
R02/R03:
The switch is located on the dashboard on the right

next to the instrument panel.
S479
T 67 4.06 - 1
Design
B110
The pulse generator delivers real-time pulses and
coded data for recording the mileage and road
speed. It has a 4-pole connection and is electrically
connected to the tachograph which sends com-
mands and data to the pulse generator at regular
10-second intervals when the vehicle is operational.
The pulse generator and the tachograph together
form a tamper-proof unit.
The pulse generator is fitted on the left of the gear-

box (looking towards the front of the vehicle).
B110
T 67 4.07 - 1
WIRING DIAGRAMS
Table of contents
Diagram title Diagram no. Section/page

Guide to using the wiring diagrams 6.01 - 1
Installation positions, TG-A 6.01 - 2
Installation positions, R02 6.01 - 6
Overview, Intarder EST 48 (TG-A) 6.05 - 2
Overview, Intarder EST 48 (R02/R03) 6.06 - 2
Wiring diagram, Intarder EST 48 (TG-A) 81.99192.1378 6.20 - 2
Wiring diagram, drive module, Intarder EST 48 81.99289.5770 6.21 - 2
(R02/R03)
Wiring diagram, Intarder EST 48 (R02/R03) 81.99289.5808 6.22 - 2
T 67 6.00 - 1
WIRING DIAGRAMS
Guide to using the wiring diagrams
1 Component designation (here: Diode V100, central electrical system, number 53)
2 Installation position at the front end of the central electrical system (here: Stamped number 53)
3 Plug connection at the rear end of the central electrical system (here: Plug 78, connection 8)
4 Line number; repeatedly printed along the length of the wire (cross-section is only printed if larger
than 12)
5 Sheet number (not page number) and current path number
Indication of sheet number and current path on which the line continues
(here: Line 31002 continues on sheet 2 and current path 4)
6 Plug connection (here: 1-pole plug connection X104 in CES area)
7 Component installation position (here: 21-pole plug connection X238 pin R
– cab to engine cable line – in mid-section)
8 Current path number (Important: Each sheet is again numbered from 1 to 55)
Important note regarding use of the diagram keys: Some of the item numbers are followed by a three-
digit number in brackets. This three-digit number is the component code number!
These code numbers appear on the list of equipment in T60
T 67 6.01 - 1
WIRING DIAGRAMS
Installation positions for left-hand drive vehicles (TG-A)
6.01 - 2 T 67
WIRING DIAGRAMS
Identifier Installation position
A
.................................................................................................. Rear of vehicle
B1
.................................................................................................. Engine
B2
.................................................................................................. Gearbox
C
.................................................................................................. Front of vehicle
C1
.................................................................................................. Bumper
C2
.................................................................................................. Right-hand entry point
C3
.................................................................................................. Left-hand entry point
E6
.................................................................................................. Area of central electrical system
E7
.................................................................................................. Control unit plug-in modules
E8
.................................................................................................. Back wall of cab
F
.................................................................................................. Instrument panel
F1
.................................................................................................. Mid-section
F2
.................................................................................................. Steering column/steering wheel
F3
.................................................................................................. Pedals
F4
.................................................................................................. Front wall inside left
F5
.................................................................................................. Front wall inside right
F6
.................................................................................................. Driver’s seat
F7
.................................................................................................. Co-driver’s seat
F8
.................................................................................................. Gearshift console
G
.................................................................................................. Battery box
H1
.................................................................................................. B-pillar, driver's side
H2
.................................................................................................. A-pillar, driver's side
J1
.................................................................................................. B-pillar, co-driver's side
J2
.................................................................................................. A-pillar, co-driver's side
L
.................................................................................................. Ceiling/roof
N
.................................................................................................. Front axle
P
.................................................................................................. Rear axle
R1
.................................................................................................. Front frame sections
R2
.................................................................................................. Rear frame section
S1
.................................................................................................. Left-hand door
S2
.................................................................................................. Right-hand door
T 67 6.01 - 3
WIRING DIAGRAMS
Installation positions for right-hand drive vehicles (TG-A)
6.01 - 4 T 67
WIRING DIAGRAMS
Identifier Installation position
A
.................................................................................................. Rear of vehicle
B1
.................................................................................................. Engine
B2
.................................................................................................. Gearbox
C
.................................................................................................. Front of vehicle
C1
.................................................................................................. Bumper
C2
.................................................................................................. Right-hand entry point
C3
.................................................................................................. Left-hand entry point
E6
.................................................................................................. Area of central electrical system
E7
.................................................................................................. Control unit plug-in modules
E8
.................................................................................................. Back wall of cab
F
.................................................................................................. Instrument panel
F1
.................................................................................................. Mid-section
F2
.................................................................................................. Steering column/steering wheel
F3
.................................................................................................. Pedals
F4
.................................................................................................. Front wall inside left
F5
.................................................................................................. Front wall inside right
F6
.................................................................................................. Driver’s seat
F7
.................................................................................................. Co-driver’s seat
F8
.................................................................................................. Gearshift console
G
.................................................................................................. Battery box
H1
.................................................................................................. B-pillar, driver's side
H2
.................................................................................................. A-pillar, driver's side
J1
.................................................................................................. B-pillar, co-driver's side
J2
.................................................................................................. A-pillar, co-driver's side
L
.................................................................................................. Ceiling/roof
N
.................................................................................................. Front axle
P
.................................................................................................. Rear axle
R1
.................................................................................................. Front frame sections
R2
.................................................................................................. Rear frame section
S1
.................................................................................................. Left-hand door
S2
.................................................................................................. Right-hand door
T 67 6.01 - 5
WIRING DIAGRAMS
Installation positions, R02
Location identifiers Installation position
A .............................................................................................................. Rear of vehicle

B .............................................................................................................. Engine, gearbox
C .............................................................................................................. Front of vehicle
D .............................................................................................................. Main switchboard
E .............................................................................................................. Equipment compartment (battery box)
E1 .............................................................................................................. Equipment board 1 (sec. switchboard)
E6 .............................................................................................................. Area of central electrical system (CES)
E7 .............................................................................................................. Control unit plug-in modules
F .............................................................................................................. Instrument panel
G .............................................................................................................. Battery box (front)
G1 .............................................................................................................. Battery box (rear)
H .............................................................................................................. Left-hand side of vehicle
J .............................................................................................................. Right-hand side of vehicle
K .............................................................................................................. Middle of vehicle
L .............................................................................................................. Ceiling
N .............................................................................................................. Front axle
P .............................................................................................................. Rear axle
6.01 - 6 T 67
WIRING DIAGRAMS
T 67 6.05 - 1
WIRING DIAGRAMS
Overview, Intarder EST 48 (TG-A)
Key
Modification status: 04.01
A100 Central electrical system

A143 Control unit, ECAS
A144 Control unit, retarder
A312 Customer-specified control module
A302 Central computer 2
A330 Control unit, AS-TRONIC (on gearbox)
A384 Control unit, rear axle steering
A402 Control unit, EBS
A403 Vehicle management computer
A407 Instrumentation
A408 Tachograph Line colours
A409 Control unit, ECAM
blrt Blue/red
A437 Steering column stalk, retarder
blws Blue/white
A551 Control unit, oil level sensor
blge Blue/yellow
B110 Pulse generator, tachograph
gebl Yellow/blue
B134 Temperature sensor, coolant (retarder)
gr Grey
F125 Fuse, instrument, switch and location lighting grbr Grey/brown
F152 Fuse, retarder (terminal 15) grgn Grey/green
F374 Fuse, Intarder/retarder (terminal 30) grws Grey/white
F583 Voltage supply, vehicle management computer
(terminal 15)
H145 Check lamp, retarder
S284 Switch, RSG/RSL
S479 Switch, sustained-action brake
X200 Plug connection, diagnosis (MAN-cats)
X1559 Plug connection, engine/EDC/gearbox IV
X2043 Plug connection, adaptation, AS-TRONIC
X1642 Earthing point, cab, next to instrument panel
X2400 Crimped connector, line, blue/red
X1644 Earthing point, cab, next to central electrical system
X2401 Crimped connector, line, blue/white
X1826 Crimped connector, line 31000 X2544 Potential distributor, 21-pole, K-line
X1827 Crimped connector, line 31000 Y133 Proportional valve, retarder
X1831 Crimped connector, line 60028 Y134 2/3-way valve, retarder
X1832 Crimped connector, line 60028
T 67 6.05 - 2
WIRING DIAGRAMS
Overview, Intarder EST 48 (TG-A)
T 67 6.05 - 3
WIRING DIAGRAMS
T 67 6.06 - 1
WIRING DIAGRAMS
Overview, Intarder EST 48 (R02/R03)
Key
Modification status: 10.00
A100 Central electrical system

A143 Control unit, ECAS
A144 Control unit, retarder
A330 Control unit, AS-TRONIC (on gearbox)
A402 Control unit, EBS
A408 Tachograph
A409 Control unit, ECAM
A437 Steering column stalk, retarder Line colours
B110 Pulse generator, tachograph
B134 Temperature sensor, coolant (retarder) blrt Blue/red
F125 Fuse, instrument, switch and location lighting blws Blue/white
F152 Fuse, retarder (terminal 15) blge Blue/yellow
F372 Voltage supply, vehicle management computer gebl Yellow/blue
(terminal 15) gr Grey
F374 Fuse, Intarder/retarder (terminal 30) grbr Grey/brown
H145 Check lamp, retarder grgn Grey/green
S284 Switch, RSG/RSL grws Grey/white
S479 Switch, sustained-action brake
X200 Plug connection, diagnosis (MAN-cats)
X615 Distributor, line 31000
X1908 Crimped connector, K-KWP2
Y133 Proportional valve, retarder
Y134 2/3-way valve, retarder
T 67 6.06 - 2
WIRING DIAGRAMS
Overview, Intarder EST 48 (R02/R03)
T 67 6.06 - 3
WIRING DIAGRAMS
T 67 6.20 - 1
WIRING DIAGRAMS
Intarder ZF-EST 48 (TG-A)

Codes for installation positions
Key
Diagram no. 81.99192.1378 Sheet 1 of 1 A Rear of vehicle F6 Driver’s seat
Modification status: 04.01 B1 Engine F7 Co-driver’s seat
B2 Gearbox F8 Gearshift console
A = Sustained-action brake lever
B = Temperature sensor C Front of vehicle G Battery box
C = Solenoid valve C1 Bumper H1 B-pillar, driver's side
D = Diagnosis C2 Right-hand entry point H2 A-pillar, driver's side
E = Voltage supply C3 Left-hand entry point J1 B-pillar, co-driver's side
A100 (255) Central electrical system E6 Area of central electrical system J2 A-pillar, co-driver's side
A144 (451) Control unit, retarder E7 Control unit plug-in modules L Ceiling/roof
A302 (352) Central computer 2 E8 Back wall of cab N Front axle
A403 (339) Vehicle management computer
A407 (342) Instrumentation
F Instrument panel P Rear axle
A437 (398) Sustained-action brake lever F1 Mid-section R1 Front frame section
F2 Steering column/steering wheel R2 Rear frame section
B134 (155) Temperature sensor, coolant (retarder) F3 Pedals S1 Left-hand door
F152 (101) Fuse, retarder (terminal 15) F4 Front wall inside left S2 Right-hand door
F374 (101) Fuse, retarder (terminal 30) F5 Front wall inside right
H145 Check lamp, retarder
X1553 Plug connection, engine/EDC/gearbox III

X1559 Plug connection, engine/EDC/gearbox IV
X1644 Earthing point, cab, next to central electrical system
X1948 Plug connection, engine/gearbox (engine power box)
X1969 Plug connection, engine brake switch
X2544 (246) Potential distributor, 21-pole, K-line
Y133 (182) Proportional valve, retarder

Y134 (123) Solenoid valve, accumulator
T 67 6.20 - 2
WIRING DIAGRAMS
Diagram no. 81.99192.1378 Sheet 1 of 1
T 67 6.20 - 3
WIRING DIAGRAMS
T 67 6.21 - 1
WIRING DIAGRAMS
Drive module, Intarder EST 48 (R02/R03)

Key
Diagram no. 81.99289.5770 Sheet 1 of 1 A Rear of vehicle F Instrument panel
Modification status: 08.00 B Engine, gearbox G Battery box (front)
C Front of vehicle G1 Battery box (rear)
A = Voltage supply, Intarder control
B = Temperature sensor D Main switchboard H Left-hand side of vehicle
C = Solenoid valves E Equipment compartment (battery box) J Right-hand side of vehicle
D = T-CAN interface E1 Equipment board 1 (sec. switchboard) K Middle of vehicle
E6 Area of central electrical system (CES) L Ceiling
A100 (255) Central electrical system
A144 (451) Control unit, retarder E7 Control unit plug-in modules N Front axle
A302 (352) Central computer 2 P Rear axle
B134 (155) Temperature sensor, coolant (retarder)
F152 (101) Fuse, retarder

F374 (101) Fuse, Intarder/retarder (terminal 30)

X2304 Plug connection, Gearbox/retarder, drive module

Y134 (123) 2/3-way valve, retarder
T 67 6.21 - 2
WIRING DIAGRAMS
T 67 6.21 - 3
WIRING DIAGRAMS
T 67 6.22 - 1
WIRING DIAGRAMS
Intarder EST 48 (R02/R03)

Key
A = Voltage supply, ZF-Intarder control
B = Temperature sensor D Main switchboard H Left-hand side of vehicle
C = Solenoid valves E Equipment compartment (battery box) J Right-hand side of vehicle
D = Diagnosis, Intarder E1 Equipment board 1 (sec. switchboard) K Middle of vehicle
E = Check lamps E6 Area of central electrical system (CES) L Ceiling
A100 (255) Central electrical system E7 Control unit plug-in modules N Front axle
A144 (451) Control unit, retarder P Rear axle
A407 (342) Instrumentation
B134 (155) Temperature sensor, coolant (retarder)
F152 (101) Fuse, retarder

F374 (101) Fuse, Intarder/retarder (terminal 30) I Additional wiring diagram, EBS
H145 Check lamp, retarder II Additional wiring diagram, voltage supply
X404 Plug connection, cab, gearbox III Additional wiring diagram, ECAM
X615 (211) Distributor, terminal board X613, line 31000
X1553 Plug connection, engine/EDC/gearbox III
X2304 Plug connection, Gearbox/retarder, drive module

Y134 (123) 2/3-way valve, retarder
T 67 6.22 - 2
WIRING DIAGRAMS
T 67 6.22 - 3
WIRING DIAGRAMS
Intarder EST 48 (R02/R03)

Key
A = Sustained-action brake lever
D Main switchboard H Left-hand side of vehicle
A100 (255) Central electrical system E Equipment compartment (battery box) J Right-hand side of vehicle
A302 (352) Central computer 2 E1 Equipment board 1 (sec. switchboard) K Middle of vehicle
A437 Steering column stalk, retarder
E6 Area of central electrical system (CES) L Ceiling
E7 Control unit plug-in modules N Front axle
X1969 Plug connection, engine brake switch P Rear axle
T 67 6.22 - 4
WIRING DIAGRAMS
T 67 6.22 - 5
DIAGNOSIS
Diagnosis socket (X200)
The SPN fault codes can be read out from the fault memory of various control units using MAN-cats II
(connection on diagnosis socket X200). The results are displayed on the MAN-cats display.
View of socket X200, line side
8 1
7 9 2
12 10
6 11 3
5 4
Central arrow
points towards pin 1
− TG-A:
Diagnosis socket X200 Address
Pin Function Terminal Line number From CES pin
4 K line 16202 Via X2544 to the control units

KWP 2000
9 Negative 31 31000 Earthing point, central
potential electrical system
X1644 via X1829
10 Voltage supply 30 30009 Via X1535 to fuse F412/10A A2/11
11 Voltage supply 15 16000 Via X1833 to fuse F376/10A F/3
12 Signal, alternator W 59101 Alternator G102 pin 1
− R02/R03:
Diagnosis socket X200 Address
Pin Function Terminal Line number From CES pin
4 K line 16202 Via X1908 to the control units

KWP 2000
9 Negative 31 31000 Earthing point, central
potential electrical system (item 92)
10 Voltage supply 30 30009 Fuse F412/10A A2/11
11 Voltage supply 15 16000 Via X362 to fuse F/3
F376/10A
12 Signal, alternator W 59101 Alternator G102 pin 1
T 67 8.03 - 1
DIAGNOSIS
1
TG-A:
The diagnosis socket 1 is located on the rear side of

the central electrical system.
R02/R03:
The diagnosis socket 1 is positioned on the left 1

under the driver's seat.
8.03 - 2 T 67
DIAGNOSIS
Fault code
The main functions of diagnosis are:

− Fault detection
− Fault analysis
Occurrence
Meaning
Identification
Fault type (static, sporadic,...)
− Fault saving
− Simulation for troubleshooting
Malfunction indicators
The electronic control unit (A144) has self-diagnosis functions for all outputs and various inputs. The faults
at the inputs and outputs, as well as internal faults, are detected, analysed and stored.
Restricted Intarder operation is ensured even if an electrical component fails (short-circuit, interrupt).
The faults are also indicated on the instrument panel display and/or by the central warning light (H111) in
conjunction with the gearbox status monitor check lamp (H179).
In the case of STOP warnings, the word STOP also appears on the display and the central warning light
(H111) flashes RED at 1-second intervals.
The central warning light (H111) lights up:

− YELLOW to indicate either a function or a warning
− RED to indicate a fault
Red always has priority over yellow. Functions or warnings (YELLOW) are always overridden by faults (RED).
The Intarder check lamp (H145) always lights up YELLOW.
Faults are indicated by the central warning light (H111) and supporting display message.
In the event of a CAN failure (instrumentation - central on-board computer), the central warning light (H111)
lights up RED.
All current malfunction indicators are available when the ignition is switched "ON" (terminal 15), irrespective
of the vehicle status.
The faults diagnosed and stored in the control unit may involve different risks. Therefore, each individual
fault is assigned a priority.
Indicator priorities
The display can not show all the information at once. It therefore shows information according to priorities.
Lower-priority information can be overwritten by higher-priority information.
Pieces of information that have the same priority are shown alternately if there is not enough room on the
display.
Diagnosis requires priorities 1 - 5.
Some function indicators have the same or a higher priority than fault indicators. In other words, a
function indicator (YELLOW) can have the same priority as a RED fault or even a STOP fault.
If the display area is already full and additional function indicators and fault indicators with the same
priority occur, the function indicator is given priority.
T 67 8.10 - 1
DIAGNOSIS
Indicator/diagnosis priorities
Diagnosis priority Indicator meaning Colour of central Diagnosis meaning

warning light (H111)
1 Indicator critical to RED flashing Drivability or safety is endangered
safety (STOP fault, RED)
2 Indicator critical to RED steady light Driving information with
functioning recommended action, check
(RED fault)
3 Indicator not necessary YELLOW steady light Information before starting to drive
for purely normal or active safety not restricted
operation (YELLOW fault)
4 --- --- No effect on drivability
5 Information about fault YELLOW steady light Warning
whilst vehicle in motion (YELLOW fault)
The display only ever shows one fault at a time.
Structure of fault texts in diagnostic message
There are 2 lines of 16 characters available for the fault texts in the diagnostic message.
The fault text message structure always includes

− fault location/fault designation
− fault information/recommended action
There are 2 types of fault text messages:

− global fault text messages
− concrete fault text messages
Global fault text message
In the global fault text message, only the priority and the source address from the DM1 message
(diagnosis message 1) are evaluated. A general message is displayed, indicating the defective system
and the transmitted fault number.
Diagnosis Central Fault text Remarks

priority warning light 1234567890123456
1 RED Sysname no. xxxxx-yy In conjunction with STOP symbol.
flashing Diagnosis Engine must be stopped!
2 RED Sysname no. xxxxx-yy Possibly workshop-relevant fault!
steady light Diagnosis Indicates malfunction
3 YELLOW Sysname no. xxxxx-yy Display at standstill, fault info. only;
steady light Diagnosis no recommended action necessary
4 --- --- No display
5 YELLOW Sysname no. xxxxx-yy Display when vehicle in motion and at
steady light Diagnosis standstill; fault info. only
− "Sysname": Indicates the defective system from the source address of DM1 (e.g.: RET S)
− "xxxxx": Indicates the fault number (04002) from the fault location number SPN in the DM1
message
SPN --> Suspect Parameter Number (fault location)
8.10 - 2 T 67
DIAGNOSIS
Concrete fault text message
In the case of the concrete fault text message, the priority, SPN fault number and fault type (FMI)
transmitted in the DM1 message are also evaluated. There is concrete recommended action and concrete
naming of the fault cause.
The SPN fault number is not displayed in the case of concrete fault text messages. The concrete fault text
message is triggered when the source address of the DM1 message "Onboard Diagnostic Unit" is
indicated.
Diagnosis Central Fault text Remarks

priority warning light 1234567890123456
1 RED Sysname no. xxxxx-yy In conjunction with STOP symbol.
flashing Diagnosis Engine must be stopped!
2 RED Sysname no. xxxxx-yy Possibly workshop-relevant fault!
steady light Diagnosis Indicates malfunction
3 YELLOW Sysname no. xxxxx-yy Display at standstill, fault info. only;
steady light Diagnosis no recommended action necessary
4 --- --- No display
5 YELLOW Sysname no. xxxxx-yy Display when vehicle in motion and at
steady light Diagnosis standstill; fault info. only
− "Sysname": Indicates the defective system from the source address of DM1 (e.g.: RET S)
− "xxxxx": Indicates the fault number from the fault location number (SPN) in the DM1 message
(e.g.: RET S no. 04002)
− "yy": Indicates the fault type number (FMI) (e.g.: RET S no. 04002-06)

FMI --> Failure Mode Identification (fault type)
Note: Several different faults can trigger the same concrete fault text message.
Safety and emergency functions
Restricted Intarder operation is ensured in the event of an fault or failure of an electrical component
(short-circuit, interrupt).
The electronic control unit (A144) detects the Intarder output speed from the pulse generator KITAS (B110)
via the tachograph (A408) and the input speed as engine speed with the help of the EDC control unit.
The vehicle management computer (A403) forwards this information to the electronic control unit (A144)
via the "drive train" CAN databus (T-CAN).
If a signal is outside of the valid range, the electronic control unit (A144) reduces the braking power to
braking level 2 (even if a higher braking level was engaged).
The Intarder remains operational, albeit with lower braking power.
If the steering column stalk (A437) suffers a defect or interrupt, the maximum braking level that is
activated is the level that matches the number of intact braking level signals.
In the event of braking level 1 signal failure, the Intarder is switched off.
In the event of temperature sensor (B134) failure, the electronic control unit (A144) reduces the braking
power to braking level 2 (even if a higher braking level was engaged).
The Intarder still remains operational even if the braking level is reduced.
The Intarder is automatically deactivated in the event of a proportional valve (Y133) fault or defect.
In the event of an accumulator solenoid valve (Y134) defect or fault, the braking power is not reduced,
i.e. the response time is longer when the Intarder is switched on.
T 67 8.10 - 3
DIAGNOSIS
Assignment of send message addresses
The electronic control unit (A144) receives various information via the CAN databus. The control units
transmit a send message address for this purpose. These addresses can be assigned to the control units.
The following list can be used to pinpoint the source of the fault.
EEC1 Electronic Engine Controller comes from EDC control unit
TSC1 Torque Speed Control comes directly from vehicle management computer
ETC1 Electronic Transmission Controller comes from AS-Tronic gearbox control unit or
comes directly from vehicle management computer;
however, only in the case of manual gearbox
ERC1 Electronic Retarder Controller comes from retarder control unit
TCO1 Tachograph comes from central on-board computer
8.10 - 4 T 67
DIAGNOSIS
On-board diagnosis
Fault indication on request (Baseline instrumentation)
Faults present can be read out on the driver's display using the menu structure from the main "Diagnosis"
menu.
Check whether there is a fault indicated:
The menu structure is controlled using buttons 1 and 2 .

There are two ways of using the buttons:
PRESSING and TOUCHING
− PRESSING - press and hold (for more than 3
seconds), e.g. to call up the menu or to confirm.
− TOUCHING - briefly press (for less than 2 seconds),
e.g. to scroll through the menu or to exit the menu.
The functions performed by button 1 are indicated by

left-hand icon 3 whilst those performed by button 2 are
indicated by right-hand icon 4 on the driver's display.
How to access the menu structure: Press button 1 MENU

(>3 sec):
> VEHICLE CONFIG.
Various menus are available, depending on the vehicle OPERATING DATA
operating state:
DIAGNOSIS
Operating state Available main menus
Ignition on VEHICLE CONFIG.
Vehicle stationary OPERATING DATA
Engine off. DIAGNOSIS
LAMP TEST
MAINTENANCE
1ST REGISTERED
TRAILER CONFIG.
Ignition on
Vehicle stationary OPERATING DATA
Engine on.
Press button 1 (<2 sec) to switch from a main menu to another menu.
Press button 2 (<2 sec) to access the submenus in the current main menu.
Main menu display (depending on the vehicle operating state):
VEHICLE OPERATING DIAGNOSIS LAMP TEST MAINTENANCE 1ST TRAILER CONFIG.

CONFIG. DATA REGISTERED
Button 2 Button 2 Button 2 Button 2 Button 2 Button 2 Button 2
Submenu Submenu Submenu Submenu Submenu Submenu Submenu
T 67 8.10 - 5
DIAGNOSIS
The "DIAGNOSIS" main menu contains further submenus, the number of which depends on how many
systems are installed in the vehicle (e.g. ZBR, EBS, ECAM, EDC, FFR, DIAG, ECAS, RET S, TCU, INST).
These submenus display the content of the relevant fault memory.
Ignition on
Button 3>3 sec MENU

OPERATING DATA
Button 3<2 sec >DIAGNOSIS
LAMP TEST
ê è
Button 4<2 sec
DIAGNOSIS
>ZBR
EBS
ECAM
ê è
Button 3<2 sec Button 4<2 sec
DIAGNOSIS
EBS ZBR error!
>ECAM Code ê OK
EDC
ê è
Button 4<2 sec
DIAGNOSIS
INST ECAM error!
>------------- Code ê OK
ë OK
Button 4<2 sec
8.10 - 6 T 67
DIAGNOSIS
Fault indication on request (Highline instrumentation)
Faults present can be read out on the driver's display using the vehicle menu from the main "Diagnosis"
menu.
Vehicle menu button 1

− Press to call up the vehicle menu
3 4
Rotary/pressure switch button 2 1
− Turn (anti-clockwise/clockwise) to select menu item
− Press to call up a menu item
Previous menu button 3

− Press to exit a menu item
2
Exit menu button 4
− Press to exit the selected menu
(e.g. diagnosis).
Calling up the "Diagnosis" vehicle menu
Check whether there is a fault indicated:
The "Diagnosis" vehicle menu is called up when the

vehicle is stationary. Vehicle menu
− Press the "Vehicle menu" button 1 until the vehicle
menu appears on the driver's display (Instr. config.,
Instr. config.
Trip data, Operating data, Vehicle config., Trip data
Maintenance ....). Operating data
The 1st menu item ("Instr. config.") is marked. Vehicle config.
Maintenance
− Turn the rotary/pressure-operated switch 2 and

select the "Diagnosis" menu item 5 .
The selected menu item is marked with a bar.
− Press rotary/pressure-operated switch, call up
"Diagnosis".
Vehicle menu
Note: Pressing the "Previous menu" button 3
enables you to leave the menu item you have Trip data
just selected without leaving the vehicle Operating data
menu. Vehicle config.
Maintenance
Leaving the vehicle menu 5
− Press the "Exit menu" button 4 .
Diagnosis
The "DIAGNOSIS" main menu contains further submenus, the number of which depends on how many
systems are installed in the vehicle (e.g. ZBR, EBS, ECAM, EDC, FFR, DIAG, ECAS, RET S, TCU, INST).
These submenus display the content of the relevant fault memory.
T 67 8.10 - 7
DIAGNOSIS
The table below explains what the abbreviations used in the submenus mean:
Abbreviations Meaning
ZBR Central on-board computer 2
EBS Electronic brake system
ECAM Electronically controlled air management
EDC Electronic diesel control
FFR Vehicle management computer
DIAG Entire vehicle (on-board diagnosis memory)
ECAS Electronically controlled air suspension
RET S Retarder/Intarder, secondary
TCU Transmission control unit (automated/automatic gearbox)
INST Instrumentation
ACC Adaptive cruise control
KSM Customer-specified module
M-TCO Tachograph
If buttons 1 or 2 are not pressed within a certain time (approx. 30 seconds), the menu structure
disappears automatically and is replaced by the display that appeared before the menu structure was
accessed.
SPN - fault code list
The following table lists the fault codes that can be read out via diagnosis socket X200 using the MAN-cats
diagnosis system in the event of a fault (SPN - Suspect Parameter Number - fault location).
Address: 2d control unit, Intarder
SPN Address SPN plain text

04001 2d Accumulator charge valve
04002 2d Request, engine brake
04003 2d Intarder, check lamp
04004 2d Display, temperature reduction control
04005 2d Brake lamp output
04006 2d Fault lamp output
04007 2d Cruise control shut-off
04008 2d Supply, steering column stalk
04009 2d Proportional valve
04010 2d Earth return, proportional valve
04011 2d Output, ADM2
04012 2d Speed sensor, gearbox output
04013 2d Temperature recording, system fault
04014 2d Readback current, proportional valve
04015 2d Voltage supply
04016 2d Braking level selector
04017 2d Operating hours counter, system fault
04018 2d Fault memory, system fault
04019 2d CAN databus
8.10 - 8 T 67
DIAGNOSIS
SPN - fault code list
SPN Address SPN plain text

04020 2d CAN databus, message EEC2 from EDC
04021 2d Speed sensor, engine
04022 2d System fault
04023 2d CAN databus, message TSC1 from FFR
04024 2d CAN databus, send, system fault
04025 2d CAN databus, BusOff
04026 2d CAN databus, message EBC1 from EBS/ABS
04027 2d CAN databus, acknowledge, system fault
04028 2d CAN databus, message EEC1 from EDC
04029 2d CAN databus, message TCO1 from tachograph
04030 2d Light-emitting diode
04031 2d CAN databus, message CCVS from FFR
04032 2d CAN databus, message ERC1_ER from EDC
04033 2d CAN databus, message ETC1 from gearbox
04034 2d CAN databus, message ETC1 from FFR
04035 2d CAN databus, message ETP from EDC
04036 2d CAN databus, message ERC1 from FFR
04037 2d CAN databus, message TSC1 from FFR
04038 2d CAN databus, message Time/Date from tachograph
04039 2d CAN databus, message mileage (HRVD) from tachograph
04040 2d Bremsomat active lamp
04041 2d CAN databus, message ABS from EBS/ABS
04042 2d CAN databus, message FMR1 from FFR
04043 2d Flashing code lamp
04044 2d CAN databus, message FMR2
04045 2d CAN databus, message EPS
04047 2d Vehicle power supply, terminal 30
T 67 8.10 - 9
DIAGNOSIS
Address directories
Address Control unit Address Control unit

1 CRT 38 ECAS/EFR
10 EDC 61 Instrumentation
14 EDC 7 Master 98 GKR air conditioning
15 EDC 7 Slave 9A T50/AT 3500
18 AS-Tronic 9A D5W SC
19 WSK 9C AT 3500
20 FFR 9C D1LC/D3LC
21 ZBR 2 a8 Door module, driver's seat
22 ECAM a9 Door module, co-driver's seat
2a EBS c2 Airbag
2c WaPu DO KSM
2d Intarder E8 LGS
31 RAS-EC1 fb ZBR 2 OBDU
8.10 - 10 T 67
DIAGNOSIS
SPN - fault code description
The following fault codes, which are indicated by check lamps (lighting up on the panel of check lamps or
as icon on the display) and with the help of the MAN-cats screen, are now documented individually. The
faults are entered in the fault memory of the Intarder electronic control unit (A144). The fault memory is
read out using MAN-cats II.

SPN Plain text (fault location) Priority FMI Fault type

04001 Accumulator charge valve 1 5 Short-circuit to ground
1 6 Short-circuit to UBat (positive)
1 10 Interrupt
04002 Request, engine brake 1 5 Short-circuit to ground
1 10 Interrupt
04003 Intarder, check lamp 1 5 Short-circuit to ground
1 10 Interrupt
04004 Display, temp. reduction control 5 Short-circuit to ground
6 Short-circuit to UBat (positive)
10 Interrupt
04005 Brake lamp output 1 5 Short-circuit to ground
1 10 Interrupt
04006 Fault lamp output 5 Short-circuit to ground
10 Interrupt
04007 Cruise control shut-off 5 Short-circuit to ground
10 Interrupt
04008 Supply, steering column stalk 1 5 Short-circuit to ground
1 10 Interrupt
04009 Proportional valve 1 5 Short-circuit to ground
1 9 Device fault
1 10 Interrupt
04010 Earth return, proportional valve 1 5 Short-circuit to ground
04011 Output ADM2 5 Short-circuit to ground
10 Interrupt

T 67 8.11 - 1
DIAGNOSIS

04012 Speed sensor, gearbox output 1 4 No signal available
Speed recording, gearbox output, 0 ---
system fault
04013 Temperature recording, system fault 1 10 Interrupt
Temperature sensor
1 7 General short-circuit
04014 Readback current, proportional valve 1 2 Too low
1 1 Too high
Readback current, system fault 0 ---
04015 Voltage supply (terminal 15) 1 1 Too high
Voltage supply, system fault 1 2 Too low
04016 Braking level selector 1 3 Implausible
Braking level selector, system fault 0 ---
04017 Operating hours counter, system fault 3 0 ---
04018 Fault memory, system fault 3 0 ---
04019 CAN databus 9 Device fault
04020 CAN databus, message EEC2 from 4 No signal available
EDC
04021 Speed sensor, engine 4 No signal available
Speed recording, engine, system fault 0 ---
04022 System fault 1 0 ---
04023 CAN databus, message TSC1 from 1 4 No signal available
FFR
04024 CAN databus, send, system fault 1 0 ---
04025 CAN databus, BusOff 1 9 Device fault
04026 CAN databus, message EBC1 from 4 No signal available
EBS/ABS
04027 CAN databus, Acknowledge, 1 0 ---
system fault
04028 CAN databus, message EEC1 from 1 4 No signal available
EDC
04029 CAN databus, message TCO1 from 1 4 No signal available
tachograph
04030 Light-emitting diode 1 5 Short-circuit to ground
1 10 Interrupt
04031 CAN databus, message CCVS from 4 No signal available
FFR
04032 CAN databus, message ERC1_ER 4 No signal available
from EDC
04033 CAN databus, message ETC1 from 4 No signal available
gearbox

8.11 - 2 T 67
DIAGNOSIS

04034 CAN databus, message ETC1 from 4 No signal available
FFR
04035 CAN databus, message ETP from 4 No signal available
EDC
04036 CAN databus, message ERC1 from 4 No signal available
FFR
04037 CAN databus, message TSC1 from 4 No signal available
FFR
04038 CAN databus, message Time/ 1 4 No signal available
Date from tachograph
04039 CAN databus, message mileage 1 4 No signal available
(HRVD) from tachograph
04040 Bremsomat active lamp 1 5 Short-circuit to ground
1 10 Interrupt
04041 CAN databus, message ABS from 4 No signal available
EBS/ABS
04042 CAN databus, message FMR1 from 4 No signal available
FFR
04043 Flashing code lamp 5 Short-circuit to ground
10 Interrupt
04044 CAN databus, message FMR2 4 No signal available
04045 CAN databus, message EPS 4 No signal available
04047 Vehicle power supply, terminal 30 1 10 Interrupt

Definition of fault types (FMI)
Fault type (FMI) Description

1 Too high
2 Too low
3 Implausible
4 No signal available
5 Short-circuit to ground
7 General short-circuit
8 Defective signal
9 Device fault
10 Interrupt
T 67 8.11 - 3
8.11 - 4 T 67
DIAGNOSIS
System structure, K-lines
− TG-A
All the control units testable using the MAN-cats diagnosis system are connected with diagnosis socket
X200 pin ... via a K-line. The diagnosis system stimulates a certain control unit via the K-line. The control
unit replies and digitally transfers the faults stored in the fault memory via the K-line.
A143 Electronically controlled air suspension A451 Door module, driver side
A144 Control, retarder/Intarder A452 Door module, co-driver side
A302 Central computer 2 A474 Air-conditioning system
A312 Customer-specified module A483 Auxiliary air heater
A330 Gearbox control, Tipmatic AS-Tronic A486 Control unit, airbag
A402 Electronic brake system A487 Electrically adjustable driver's seat
A403 Vehicle management computer A488 Electrically adjustable co-driver's seat
A407 Instrumentation A494 Auxiliary water heater
A409 Electronically controlled air management X200 Diagnosis socket
A435 Electronic diesel control
T 67 8.15 - 1
DIAGNOSIS
− R02/R03
All the control units testable using the MAN-cats diagnosis system are connected with diagnosis socket
X200 pin ... via a K-line. The diagnosis system stimulates a certain control unit via the K-line. The control
unit replies and digitally transfers the faults stored in the fault memory via the K-line.
This also applies to the multiplex central computer ZBRO (A360) which is also connected to diagnosis
socket X3090 pin S via a K-line.
A143 Electronically controlled air suspension A409 Electronically controlled air management
A144 Control, retarder/Intarder A435 Electronic diesel control
A302 Central computer 2 A451 Door module, driver side
A330 Gearbox control, Tipmatic AS-Tronic A452 Door module, co-driver side
A402 Electronic brake system X200 Diagnosis socket
A403 Vehicle management computer X3090 Diagnosis socket, multiplex
8.15 - 2 T 67

T67 2 Intarder EST48 81995985322 ENG

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Publication no.: System Description

MAN Nutzfahrzeuge Aktiengesellschaft Elektrische Anlage

We reserve the right to make modifications in the course of further development

 2002 MAN Nutzfahrzeuge Aktiengesellschaft

VSWY / WT 03.2002 Übersetzung + Satz: emes GmbH

Functional description ................................................................................................................. 3

Abbreviations As of: 04.02

CAN Controller area network

DAHL Roof ventilator

DIAK Diagnosis, K-line (data line)

EBS Electronic brake system

FAP Driver’s area

FMR Vehicle/engine management

GDK Controlled diesel catalytic converter

IBEL Interior lighting

KBZ Combination brake cylinder

LBH Air reservoir

M-TCO Modular EU tachograph

OBDU On-board diagnostic unit

UBat Battery voltage

Regulations for preventing accidents leading to injury to personnel.

• Secure the vehicle to prevent it from rolling away.

• If painting work is to be carried out, do not expose the electronic components

Plastic tubes (polyamide)

Limited liability for accessories and parts

Bodies and special attachments

Taking out of operation or putting into storage

Intarder EST 48 design

The Intarder is fitted at the output end of the gearbox.

Its main components are:

Advantages of the Intarder:

− Fast response times

IMPORTANT: The Intarder is not a parking brake!

1 Intarder EST 48 (mounted on the gearbox)

T-CAN Drive train CAN databus

CAN messages and CAN diagnosis

Scope of Intarder tasks:

Scope of electronic brake system (EBS) tasks

Scope of the vehicle management computer (FFR) tasks

Electronic control unit (A144)

− Signal from steering column stalk (A437) (braking torque is set)

Coolant temperature sensor (B134)

Proportional valve (Y133)

Accumulator solenoid valve (Y134)

Sustained-action brake switch (S479)

Steering column stalk (A437)

Intarder operating modes:

Steering column stalk operation

Move towards + Nudge: Gradual increase in the requested braking torque.

Move towards - Nudge: Gradual decrease in the requested braking torque.

Warning and diagnosis light (H145)

Pulse generator KITAS 2170 (B110)

1 04015-01 = Fault code

2 = Intarder check lamp (H145)

3 = Central warning light (H111)

Interfaces to other systems

A143 Electronic air suspension/ A403 Vehicle management computer with